C.R.

M 3

Cold Rolling Mill 3 is the designated name for the second mill and the more recent one.
Manufactured by Frohling, a leading German company, this mill is a significant upgrade to the
previous mill as it has higher rpm and reduced vibrations which leads to, faster and more
efficient rolling, and less breakdowns. It is work roll driven and reversible in nature. The
operations are executed by a control room and all machine parameters are given and controlled
by computers. The annealed coils of thickness 1.5 mm are rolled to a final thickness of 0.9 mm
through 3 continuous passes. The rolled coils are annealed again and then send to machine shop
for cutting in smaller coils etc.

Process 2nd mill 4 passes, 15 min

Mill screw down - 450 Metric Tonne

Pass Number 0 1 2 3
Thickness 1.5 mm 1.3 mm 1.1 mm 0.9 mm
Tension in 12000 N 45000 N 40000 N 32000 N
Tension out 45800 N 40000 N 35000 N 30000 N
R.P.M 140 280 280 280

Figure 1. C.R.M. – 3
4.4 Analysis

4.4.1 Cold Rolling Mill

We are using the vibrational data, to plot the graphs with the help of origin.

The data acquired by using the experimental setup is used in the origin software to generate the
graphs of all the 3 axis vibrational data with respect to time for explicit understanding of how the
machine is behaving in terms of vibrations, in real time.

The result of the graphs generated are used to analyze the data points and then observe the trends
and similarities in the behavioral pattern. These trends are further used out in the analysis of the
data.

Below are the parameters of CRM – 2:

Material being rolled - C 75 Grade Steel

Number of passes - 2

Initial Thickness - 2 mm

Final Thickness - 1.5 mm

Mill Screw Down - 225 Metric Tonne

Friction Factor = 0.14

Maximum Reduction Factor is 2.94

Flow stress=441.438 MPa

Roller force=3779.28 KN

Torque = 11571.59 Nm

Power = 363.53 KW

Bite angle= 2.431 degrees

Width of sheet is 1500 mm

Roller Diameter is 400 mm

Figure 2. Acquired Data for X, Y, Z axes for C.R.M. – 2
Figure 3. Graphical representation of acquired data for X, Y, Z axes (C.R.M. – 2)

Figure 4. Graphical representation of acquired data for X-axis (C.R.M. – 2)

Figure 5. Graphical representation of acquired data for Y-axis (C.R.M. – 2)

Figure 6. . Graphical representation of acquired data for Z-axis (C.R.M. – 2)

Below are the parameters for CRM – 3:

Material being rolled - C 75 Grade Steel

Number of passes - 3

Initial Thickness - 1.5 mm

Final Thickness - 0.9 mm

Mill screw down - 450 Metric Tonne

Friction Factor = 0.177

Maximum Reduction Factor is 5.78

Flow stress = 366.589 MPa

Roller force = 3478.013 KN

Torque = 10999.22 Nm

Power = 645.02 KW

Bite angle = 5.731 degrees

Width of sheet is 1500 mm

Roller Diameter is 400 mm

Figure 7. Acquired Data for X, Y, Z axes for C.R.M. – 3
Figure 8. Graphical representation of acquired data for X, Y, Z axes (C.R.M. – 3)
Figure 9. Graphical representation of acquired data for X-axis (C.R.M. – 3)

Figure 10. Graphical representation of acquired data for Y-axis (C.R.M. – 3)

Figure 11. Graphical representation of acquired data for Z-axis (C.R.M. – 3)